Terex TH636C TH644C TH842C TH844C Operator's Manual 236503 - PDF DOWNLOAD

236503

WTEREX HANDLERS OPERATOR'S MANUAL

TH636C TH644C TH842C TH844C ~ TEREX HANDLE.RS 455 N. Superior Ave. Baraga, MI 49908-0790 Ph. (906) 353-6675 Fax (906) 353-7543 http://www.terexlift.com 02/26/04

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TABLE OF CONTENTS SECTION 1

ROUGH TERRAIN FORKLIFT SAFETYSECTION Introdnction Standards And Symbols Safety Training And Knowledge Operator's Responsibilities Management's Responsibilities Maintenance And Repair Operation Safety

1-1 1-3 1-4 1-5 1-5 1-6 1-7 1-8 1-9

SECTION 2

GENERAL SAFETY General Safety Procedures Jump Starting Proper Load Chart Use

2-1 2-3 2-8 2-9

SECTION 3

CONTROLS AND INSTRUMENTS Operator's Compartment Joystick Control Functions Joystick Control Functions (Button Pushed) Service Brakes Low Service Brake Pressure Light Parking Brake Frame Sway Control Gauges Hydraulic Pump Destroke Button Steering Transmission Front Axle Differential Lock

3-1 3-3 3-4 3-5 3-6 3-6 3-7 3-8 3-9 3-9 3-10 3-10 3-11

SECTION 4

OPERATION Operation And Safety Guidelines Before Starting The Engine Starting The Engine Before Operating The Forklift Transporting A Load Placing A Load

4-1 4-3 4-4 4-9 4-11 4-15 4-17

SECTION 5

MAINTENANCE PROCEDURES General Safety Practices Servicelntervals Required Grease Intervals Grease Fitting Locations Daily Maintenance Procedures 50 Hour Maintenance Procedures 100 Hour Maintenance Procedures 250 Hour Maintenance Procedures 500 Hour Maintenance Procedures 750 Hour Maintenance Procedures 1000 Hour Maintenance Procedures 2000 Hour Maintenance Procedures Filter Guide Recommended FluidsAnd Capacities Hydraulic Pressnre Settings

5-1 5-3 5-5 5-6 5-7 5-8 5-12 5-15 5-17 5-18 5-20 5-21 5-23 5-24 5-24 5-25

SECTION 6

MATERIALSAFETYDATA Material Safety Data Sheets California Proposition 65 Warnings

6-1 6-3 6-4

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SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY

1- 1

TABLE OF CONTENTS

SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY

Introduction

1-3

Standards And Symbols

1-4

Safety

1-5

Training .And Knowledge

1-5

Operator's Responsibilities

1-6

Management's Responsibilities

1-7

Maintenance And Repair

1-8

Operation Safety

1-9

1-2

[LtROUGH TERRAIN FORK LIFT SAFETY Lt~ ~

INTRODUCTION

Owners, Users, and Operators: Terex (Handlers) appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety ifyou, as the equipment users and operators: 1. Comply with OSHA, Federal, State, and Local Regulations.

2. Read, Understand, and Follow the instructions in this and other manuals

supplied with this machine.

3. Use Good Safe Work Practices in a cornmon sense way.

4. Only have trained!certified operators - directed by infonned and

knowledgeable supervision - running the machine.

NOTE: OSHA prolnbits the alteration or modification ofthis machine without wlitten

manufacturer's approval. Use only factory approved pru1s to service or repair this machine.

If there is anything in this manual that is not clear or which you believe should be added, please send your cormnents to the Manager of Publications, Terex Handlers, P. O. Box 790, Baraga, Michigan 49908. Telephone number 906-353-6675.

Thankyout

THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED! READ, UNDERSTAND AND FOLLOW ALL DANGER, WARNING AND CAUTION DECALS ON YOUR ROUGH TERRAIN FORKLIFT.

1-3

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(&ROUGH TERRAIN FORK LIFT SAFETY ~

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STANDARDS AND SYMBOLS

STANDARDS Many aspects of rough teITaln forklift operation and testing are discussed in standards published by the American National Standards Institute. These Standards are updated on a regular basis with addendas. Terex recommends that you purchase and refer to the following standards.

ANSI B56.6 - Rough Terrain Fork Lifts This Standard can be purchased from American National Standards Institute 25 West 43nd Street, 4th Fl. New York, New York, 10036 Tel. 212.642.4900 Fax. 212.398.0023

SYMBOLS The symbols below are used to inform the operator of important infonnation concerning the operation ofthis machine.

DANGER - Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious IDJUry.

CAUTION - Indicates a potentially hazardous situation which, ifnot avoided, may result in minor or moderate IDJUry.

ATTENTION - Indicates a situation which, ifnot avoided, may result in propelty or equipment damage.

1-4

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[illROUGH TERRAIN FORK LIFT SAFETY ill] ~

SAFETY

These are general safety rules, which must be followed. You are also required to read and understand the Operator's Manual as there are instructions, which are more detailed specific to this machine.

TRAINING AND KNOWLEDGE

1. Safety must always be the operator's most important concem.

2. This machine must only be operated by trained personnel, who have demonstrated their ability to do so safely.

3. Comply with the requirements of current Occupational Safety and Health Administration (OSHA) standards, including 29CFR1910.178; and the American National Standards Institute (ANSI) B56. 6 latest edition.

4. Read and Understand all Decals and Wamings.

5. Read and Understand the Rating Chart.

6. Know that the machine can safety lift each load before attempting to lift.

1-5

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~ROUGH TERRAIN FORK LIFT SAFETY &]

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OPERATOR'S RESPONSIBILITIES

1. Read and understand the Operator's Manual.

2. Know the location and the purpose ofthe controls, instruments and indicator

lights.

3. Make sure the machine is in proper order and all operational aids and waming signals are functional before operating.

4. Keep the machine clean, including all instrumentation, windows, lights and other glazed surfaces.

5. Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, hard hats, safety glasses and ear protection where necessary.

6. Wear protective clothing that is snug and belted where required.

7. Store tools and other necessary items in the toolbox.

8. Never lift a load without a Load Rating Chad in the cab.

9. Know the load to be lifted.

10. Be aled, physically fit and free from the influences of alcohol, drugs or medications that might affect the operator's eyesight, hearing, or reactions.

11. Keep people, equipment and material out ofthe work area.

12. Keep a fully charged fire extinguisher and first aid kit in the cab at all times, and be familial'with how to use these items.

13. Know about movements of other machinery, trucks and personnel at the jobsite.

14. Make sure everyone is in a safe place before moving the boom, forks, load or outtiggers (if so equipped.)

15. Stali and stop movements smoothly and swing at speeds that will keep the load under control.

1-6

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[&~ROUGH TERRAIN FORK LIFT SAFETY &] .C

MANAGEMENT'S RESPONSIBILITIES

1. Ensure operators are competent, physically fit, trained and ifrequired licensed.

2. Have a supervisor at the job site to be responsible for job safety.

3. Crew members given specific safety responsibilities and instructed to repOlt any unsafe conditions to the supervisor.

4. Supply the weight on the load to be lifted to the operator.

5. Verify that all crewmembers are familiar with OSHA, ANSI B56.6 requirements as well as instructions in the manuals.

1-7

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[&ROUGH TERRAIN FORK LIFT SAFETY ~

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MAINTENANCE AND REPAIR

1. Practice safe maintenance procedures. Perfonn all maintenance and repairs in accordance with instructions provided by the manufacturer in the manuals. Also heed the warnings on the placards and decals on the machine.

2. Always use supports and braces when working on, under or around the machine or forks.

3. Shut offthe engine and lockout the machine while working on the machine unless instructions specifically require the engine to be running.

4. Always make sure the machine is stationary prior to performing adjustments or lubrication.

5. Replace all shields and guards after performing service.

6. Always use a piece of cardboard or paper to search for leaks.

7. When performing work on the hydraulic system: Lower the boom to horizontal. u. Support the boom with supports or braces. lJ1 Shut down the engine. iv: Relieve all pressure before disconnecting lines. v. Ensure all connections are tight before applying pressure.

VI. Repair or replace any damaged line, hose or fitting before applying pressure.

1.

8. Always have tires serviced and mounted by a qualified person with the proper tools and guards.

9. Always use an inflation cage during tire inflation.

10. Only perfonn welding on the machine with approval from the manufacturer.

1-8

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(Lt,ROUGH TERRAINFORK LIFT SAFETY ~ .~

OPERATION SAFETY

1. Always inspect the machine daily. Check for leaks, worn hoses, loose belts, broken structures, and loose or missing bolts. Repair or replace any worn, damaged or leaking parts prior to operation of the machine.

2. Only inspect the coolant level when the engine and coolant are cool.

3. Be sure that all guards and screens are secure and in the proper place.

4. Inspect for and clear the work area of any obstructions that could interfere with proper machine operation. Any obstructions that cannot be cleared should be clearly marked and avoided during operation.

5. Refueling: Always stop the engine before refueling the machine. ll. Fill the fuel tank outdoors. ill. Handle fuel with care, as it is highly flammable. Do not refuel the machine while smoking or near open flames. tv. Always clean up spilled fuel.

1.

6. Make sure the machine and access system is clean and free of diti, oil, grease or debris.

7. When getting on and off the machine, face the machine, use the steps and handrails provided, and always maintain a three point contact.

8. Always remain completely inside the cab enclosure while operating the machine.

9. Always wear the seat belt while operating the machine.

10. Always completely lower the boom with the forks resting on the ground before any work is perfOlmedon or around the machine.

11. Do not operate the machine while people are under or near an elevated boom whether the boom is loaded or unloaded. Falling objects from the forks or attachment may cause serious injury or death.

1-9

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(ffiROUGH TERRAIN FORK LIFT SAFETY ~

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OPERATION SAFETY

12. Maintain an appropriate clearance from electrical power lines. See the chart

below for minimum safe approach distances.

Minimum Safe Approach Djstance Required Clearance Power Line Voltage 10 ft. (3.00 m) o to 50 kV 50 to 200 kV 15 ft. (4.60 m) 200 to 350 kV 20 ft. (6.10 m) 25 ft. (7.62 m) 350 to 500 kV 500 to 750 kV 35 ft. (10.67 m) 45 ft. (13.72 m) 750 to 1000 kV 13. Lifting Loads:

Using the load chart, confum that the load is within the rated capacity ofthe machine for the required configuration.

11. Level the machine using the level gauge before lifting loads. Use the sway control to level the machine only when the boom is at horizontal or lower. Using the sway control with the boom above horizontal may cause the machine to overtum. lll. VerifY that the load is secured on the forks before perfonning a lift.

Rearrange the load if necessary.

IV Before lowering a maximum load, always retract the boom completely. v: Use proper attachments, such as a truss boom, to lift suspended loads.

1.

14. If the load to be lifted exceeds the capacity of the machine for the given configm-ation: 1. Move the machine closer to the load so that the weight of the load will be within the allowable load chart specifications. n. Divide the load into smaller pieces. iii. Get a lar-ger machine capable ofhandling the load.

15. Always move a load so that you have maximum machine stability and visibility is

not obstructed. Keep the boom at or below horizontaL with the load close to the ground.

16. Tilt the forks back towards the machine slightly duting travel to ensure stability of

the load.

1-10

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(ffiROUGH TERRAIN FORK LIFT SAFETY ~

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OPERATION SAFETY

17. Inspect the path oftravel before beginning movement. Avoid holes and dropoffs.

18. Traveling on slopes/grades.

1. Ascend and descend slowly and with caution. ll. When loaded, always travel with the load uphill. m. When unloaded,travel with the attachment downhill. w. Avoid tuming, travel straight up and down.

19. Always position all wheels in line with the machine before switching the steeling mode.

20. Always position the machine and set the park brake before lifting a load.

21. Do not allow riders on the machine or forks.

22. Do not transport or lift personnel into position with this forklift.

23. When leaving the operator's station: 1. Place the directional controls in neutral. ii Apply the parking brake. m. Lower the attachment to the ground.

1-11

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SECTION 2 GENERAL SAFETY

2-1

TABLE OF CONTENTS

SECTION 2 - GENERAL SAFETY

General Safety Procedures

2-3

Jump Starting

2-8

Proper Load Chart Use

2-9

2-2

LL GENERAL SAFETY LL GENERAL SAFETY PROCEDURES

SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury andlor death.

& WARNING ALWAYS wear eye protection and personal safety equipment.

THE OPERATOR The operator must be fully trained and qualified to operate this machine.

Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. [nrucator lights 4. Safety and instruction labels

ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary.

Wear protective clothing that is snug and belted where required.

FIRE PREVENTION/FIRST AID lnstall a frrst-aid kit and fire extinguisher in the operator's cab.

KEEP 1HE FIRST-AID KIT aldFlRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher.

2-3

GENERAL SAFETY GENERAL SAFETY PROCEDURES

WELDING PRECAUTIONS

& CAUTION Any unauthorized welding can cause structural failure or possible personal injury. DO NOT weld on any structural member. All unauthorized welding will void the warranty.

HAND HOLDS AND STEPS

& WARNING

[

Slips and falls can cause serious injury.

When getting on and offthe machine, always maintain a three point contact with steps and hand rails while facing the machine.

DO NOT use the steering wheel or any other controls as handrails.

NEVERjump on or offthe machine.

Be careful of slippery conditions on platforms, steps and handrails when getting on and offthe machine.

ALWAYS shut off the engine before leaving the operator's station.

REFUELING

& WARNING

....." . /

Fires can cause death or severe personal injury.

.

Handle fuel with care. It is highly flammable. DO NOT refuel the machine while smoking or when near open flames or sparks.

ALWAYS stop the engine before refueling the machine. Fill the fuel tank outdoors.

Prevent fires by keeping the machine clean of trash, grease and debris. ALWAYS clean up spilled fuel.

2-4

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it GENERAL SAFETY it GENERAL··SAFETY PROCEDURES HYDRAULIC SAFETY

& WARNING Hot hydraulic oil can cause severe burns. DO NOT work on the hydraulic system ifthe oil temperature exceeds 120degreesF. (49 degrees C).

Before ANYONE works on the hydraulic system: l.

2.

3.

4.

5.

A

Lower the boom to the horizontal position.

Support the boomto avoid unintentional lowering.

Shutdown the engine.

Remove the key from the ignition.

Clean the area around the oil reservoir cap (A).

FLUIDS UNDER PRESSURE

& WARNING Escaping fluid under pressure can penetrate the skin and can cause serious personal injury.

Use a piece of cardboard or paper to search for leaks.

00 NOT use hands. Before disconnecting hydraulic lines, be sure to relieve all line pressure. Before applying pressure to the system, be sure that all connections are tight. DO NOT apply pressure to a damaged line, hose or fitting.

If injured by escaping fluid, see a doctor at once. Proper 111 edical treatment must be administered immediately. A serious

infection or reaction can result without proper medical treatment

SERVICE TIRES SAFELY

LhWARNING An improperly mounted over-pressurized tire can result in tire explosion causing possible personal injury. An inflation cage or other safety device must be used during tire inflation.

DO NOT attempt to mount a tire unless you have the proper equipment and experience to perform the job. Ifyou do not have the proper qualifications to perform the job have your dealer or qualified repair service perform the repair.

2-5

GENERAL SAFETY GENERAL SAFETY PROCEDURES

ffi CAUTION USE SEAT BELT Always wear the seat belt while operating the machine to reduce the risk of personal injury.

ffi CAUTION -'

PRACTICE SAFE MAINTENANCE

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Unauthorized modifications to the machine may impair the safety, machine function and/or affect machine life.

}

ALWAYS use a safety support or brace when working on, lUlder. or around the machine or forks.

DO NOT adjust or lubricate the machine while it is in motion.

SHUT OFF the engine and LOCKOUTtheiguition while working on themachineunless maintenance instructions require the engine to be running.

REPLACE all the shields and guards after servicing.

NEVER use the machine as a platfonn for lifting personneL

ffi CAUTION BOOM SAFETY DO NOT enter the DANGER AREA under or around the boom when the forks are offthe ground or while the engine is running.

(See diagram at right for DANGER AREA).

Serious personal injury could result if the boom should unexpectedly drop.

Before ANY work is performed in the DANGER AREA the boom must be COMPLETELY lowered and the forks mllst be resting on the ground.

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2-6

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iE;

GENERAL SAFETY PROCEDURES

AVOID ELECTRICAL POWER LINES

ffiDANGER REQUIRED CLEARANCE FOR NORMAL VOLTAGE IN OPERATION NEAR IllGH VOLTAGE POWER LINES AND OPERATION IN TRANSIT WITH NO LOAD AND BOOM OR MAST LOWERED. Normal Voltage, kV (Phase to Phase)

Minimum Required Clearance, ft. em)

Operation Near High Voltage Power Lines to 50 Over 50 to 200 Over 200 to 350 Over 350 to 500 Over 500 to 750 Over 750 to 1000

10(3.05) 15(4.60) 20(6.10) 25(7.62) 35(10.67) 45(13.72)

Operation in Transit With No Load and Boom Lowered to 0.75

Over 0.75 to 50 Over 50 to 345 Over 345 to 750 Over 750 to 1000

4(1.22) 6«1.83) 10(3.05) 16(4.87) 20(6.10)

& WARNING Always remain completely inside the cab enclosure while operating the machine.

ffi WARNING Never operate this machine under the influence of drugs, alcohol and/or medication which can cause drowsiness.

& WARNING Never transport or lift personnel into position with this forklift. It is not designed as a personnel lifting device.

2-7

GENERAL SAFETY JUlVtP8TARTING .

Location: The battery is located under the fuel tank / battery box cover (A).

JUMP STARTING Jump starting at the battery or battery replacement is required when the battery is discharged to the point where the battery will not crank the starter.

A

itWARNING Battery posts, terminals, and related accessories contain lead and lead compOlmds, chemicals known to the State of California to cause cancer and reproductive harm.

Batteries also contain other chemicals known to the State of California to cause cancer.

Wash hands after handling.

itWARNING Never jump start the machine directly to the starter or the starter solenoid. Serious injury or death could result from the machine moving forward or backward.

itWARNING To avoid personal injury when jump starting with another machine, be certain that the machines are not touching. Never jump start a frozen battery as it will explode. Keep sparks and flames away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses when working near batteries.

The booster battery must be a 12 volt type. The machine used for jump starting must have a negative ground electrical system.

To jump start the machine, proceed as follows:

1. Connect the positive (+) jumper cable to the positive (+) post oftlle discharged battery.

2 Connect the other end of the same jumper cable to the positive (+) post of th e booster battery.

3. COlmect one end ofthe second jumper cable to the negative (-) post of the booster battery.

4. Make the final cable connection to the engine block or the furthest grou11d point away from the battery.

5. Start the engine.

6. Remove thejumpcr cables in the reverse order of their connection (i.e. negative cable ground connection first, etc.)

2-8

PROPER LOAD CHART USE

LLWARNING NEVER raise a load and drive to position it. This can cause the machine to turnover. When placing a load, always move a loaded machine with the boom angle indicator (B) at 0 degrees or less. When the machine is as close as possible to where the load needs to be placed, set the parking brake, raise the load, then place the load into position.

The load chart shows the operating limits of a properly maintained and operated machine. To use the load chart the operator must know the weight of the load and how far "out" and "up" it is to be placed. Ifthe load is heavier than stated on tbe load chart, three options can be used: 1.

Move the machine closer to the load so that the weight of tbe load win fall within the load chart specifications.

2.

Divide the load into smaller pieces so that each piece falls into load chart specifications.

3,

Get a larger machine capable ofhandling the load within specifications.

2-9

GENERAL SAFETY PROPER LOAD CHART USE

TH636C TEREX HANDLERS F'.O. BOX 790 ,',UPERIOR AVENUE BARAC,4. IvilCHIGAN 49908 PH(}>JE qos- :::\5.3- 6675 'I:'') WIRTH

FAX 906-353-7543

FEET 24 20 16 12 8 4 METER-(7,32) (6,10)(4.88) (366) (2.44)(1,22)

0

40 (12,20) I--I--Hc-I--i--i--i-f-f/

4 8 12 1 (1n) (2.44) (3.66) (4.83)

LIFT CAPACITY CHART! TH636C

36 (10,93) !--"c-I-f-l--r-r'"

MANUFACTURER'S RECOloAMENDED CAf.',4CIW PER ANSI B56.6 STA81UTi TESTS USING STANDARD FT. HOMOGENEOUS CUBES (l.;:]~I.nxl .22 LOAD CAPACITIES I'.T 24 INCH iIiIETEFS) LOAD CENTER WITH STA~J[)AI\o l'ORf( FRAME r,p,1ED LIFT CAPACITIES SHOWN ARE WITH NlACHII'JE ON A FIRM, LEVEL SURFACE WITH UNDAMAGED, PROPERU INFLATED CALCIUM CHLORIDE SOLUTION I'ILLED TIRES OF: OF'TION/\L FOAM FILLED TIRES LOAD LIMITS /

HORIZOI\lTAL BOOM

lX~T

FULLY VISIBLE LETTER HETRACTED 6,000 LBS LETTER VISIBLE 5,000 LBS LETTE~' VISIBLE 4,000 LBS LETTER VISIBLE 3,000 LBS LETTER VISIBLE 2,000 LBS FEET 24 20 16 12 8 4 METER-(732) (6,10)(4.86) (3.66) (2.44) (1 ,22)

0

4 8 1" 16 (1,22) (2,44) (3,66) (488)

TH644C TEREX HANDLERS

48

(14 64) HH--+-+++++-+--t-'H-7~

P,O, BOX 790 4~,5 nORTH SUPERIOR AVEI~UE [,N;p,Cft, wliCHI GAI'i 49908

(13.42) HH--+-+++++--b/

PHONE 006-353-6675 F,i\X 90t,-35:';-75,t3

(12.20) H-f-++++--V

44

40

MNWFACTUhER'S RECOMMENDED CAF'ACITY IS PER ANSI B56,6 STABILITY TESTS I)SI~JG STANDARD HOMOGENEOU:) CUBES FT, CI .2~~}: 1 I ~)?

LOAD CAPi>,CITIE~; AT :!4 INCH (,b I METERS I LOAD CENTER WITH ~;T4NDARD

FOHK FRAME. RATED LIFT C.'IPACITIES SHOWN ARE WITH M!',(:HINE A FIRM, LEVEL :,;Uc(Ft,CE WITH UNllAlviAGED, F'[,Uf'[RLY IhlFLATED TIRES,

em

LOA!) LllvilTS ;' HURIZOI"ITAL 800M lAST FULLY VISIBLE LETTEH PETRACTED 6,000 LBS LETTER VISIBLE 4,000 LBS LETTER VISIBLE ,3,000 LBS LETTER VISIBLE 2,000 LBS

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:':'~1274

2-10

LIFT CAPACITY CHART f TH644C

Lt GENERAL SAFETY Lt PROPER LOA))(~llART USE TH842C TEREX HANDLERS

FEETMETER-

24

20

16

12

(7,32) (6,10) (4.88) (3.66)

48 (14,64) f--t-t-t-t-t-t-t-i-i-i-+-+-+-, 44 (13.42) f--t-t-t-t-t-t-t-i-h.v MANUFACTURER'S RECOMMENDED

40 (12.20) f--l--H-l-t-t-t,,-

LIFT CAPACITY CHART I TH842C

CAPACITY IS PER ANSI 856.6 STA81l1TY TESTS USING ST,A.NDARD HUMOGENE:OUS CUBES 4x4x4 r-L (1,22:.:1.22'.(1.22 1.1ETERS). LOAD CAPACITIES Af 24 INCH (.1:11 METERS) LOAD CENTEF~ WITH

STANDARD FORK FRAME.

RATED un CAPAClTJES ARE WITH MACHINE ON A FIRM, LEVEL

SURFACE WITH UNDAMAGED. PROPERLY INFLATED CALCIUM

CHLORIDE SOLUTION' FILLED TIRES

OR OPT10I'JAl rOAM FlLUD TIRES. REAR AXLE LOCK-UP ENGAGED

LOAD LiMns / HORIZONTAL BOOM LAST FULLY VISIBLE lEHEF: RETRACTED = 8,000 LBS (A) LETIER VISIBLE ~ 6,000 LBS 4,000 LBS (C) LETTER VISIBLE"'" 3,000 lBS (D) lETIER VISIBLE: i::;" 2,000 LBS

(8) LETTER VISIBLE

TH844C TEREX HANDLERS P.O. BOX 790 45f> NORTH SUPERIOR AVENUE BARA.GA, MICHIGAN 49908

F'HOhlE 906-353-6675 FAX 906-353-7543

LIFT CAPACITY CHART I TH844C

S1ANDN\D FORK FRAME

LOAn LIMITS /

HORIZONTAL BOOM

LAST FULLY VISIBLE LEnER

FI'ETRACTED .: 8,000

f~~ tNi~~ ~:~:~t~

(C) LETIER VISIBLE (D) LEtTER VISIBLE

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3,000

'Loon

PIN 2-1286

2-11

SECTION 3 CONTROLS AND INSTRUMENTS

3-1

TABLE OF CONTENTS

SECTION 3 - CONTROLS AND INSTRUMENTS

Operator's Compatiment

3-3

Joystick Control Functions

3-4

Joystick Control Functions (Button Pushed)

3-5

Service Brakes

3-6

Low Service Brake Pressure Light

3-6

Parking Brake

3 -7

Frame Sway Control

3-8

Gauges

3-9

Hydraulic Pump Destroke Button

3-9

Steering

3-10

Transmission

3-10

Front Axle Differential Lock

3-11

3-2

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CONTROLS AND INSTRUMENTS

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OPERATOR'S COMPARTMENT 15. Parking Brake Switch

22. Heater Switch

16. Pmnp OffButton

23. Plug / Turn Signal Wires

1. Accelerator Pedal

8. Hounneter

2. Joystick 4-way Controller

9.

3. Transmission Control Lever

10. Machine Level Gauge

17.

4. Steering Selector

11. Plug / 12 Volt Access.

18. Ignition Switch

5. Service Brake Pedal

12. Seat

19.

6. Parking Brake Warning Light

13.

7. Load Chart

14. Seat Belt

Gauges

24. Interior Rear View Mirror

Front Wiper Switch

25.

Auxiliary Hydraulics

20. Steering Wheel

Frame Level Switch

Frt.Axle Differential Lock

26. Low Brake Press. Light 27.

Rear Wiper Switch

21. Headlight Switch 13

24

20 25

9

'''eel ~~

3

19

3

22 12 18--TTI~L-__~,~~

16

26

6 18 15 21 17 27

14

8 -++f-------4

4

-Hk---::::<~~;ed

5

25

FORK TILT RELAY & 4-WAY ELECTRIC TILT VALVES & AUXILIARY HYDRAULICS & SERVICE BRAKE LIGHTS & TRANSMISSION CUT·OUT RELAY & SWAY CONTROL (TH636C ONLY)

-1

ELECTRIC ETHER AID & 12 VOLT ACCESSORY PLLJQ]

FRONT AXLE DIFFERENTIAL LOCK

FUSE PANEL VIEW

3-3

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CONTROLS AND INSTRUMENTS fi

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JOYSTICKCONTROL FUNCTIONS·

A - BoomDown

A

B - BoomUp

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B

]

A

C - BoomOut D - Boomln

.. C

A

H", t/E

E - Boom Down and Out

F - Boom Up and In

0-

,

..

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... c

¥i ~ "'G

G - Boom Up and Out

~F~

H - Boom Down aud In

.~

3-4

B

[

CONTROLS AND INSTRUMENTS

« JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED) A - Tilt Down B - TiltBack

t"'~\ A

3-5

] D

CONTROLS AND INSTRUMENTS SERVICE BRAKES The brake pedal is the operator's control for the service brakes.

Pushing the service brake pedal (A) activates the service brakes for all four wheels.

The brakes should be applied during normal operation to stop machine movement.

A

LOW SERVICE BRAKE PRESSURE LIGHT

LL WARNING Insufficient hydraulic pressure to the service brakes may result in increased stopping distances causing possible injury or death and/or damage to the machine or property.

Theilluminaiiou of the "LOW BRAKE PRESSURE" light (B) when the machine is running indicates this potentially hazardous condition. Should this condition ever exist, discontinue use ofthe machine immediately. Contact a qualified service technician to resolve this problem.

3-6

CONTROLS AND INSTRUMENTS PARKING BRAKE

& WARNING Failure to set th e parking brake before leaving the machine may result in unintended machine movement and possible injury or death and/or damage to the machine or property.

The parking brake should be engaged anytime the operator gets off the machine. To engage the parking brake, toggle the parking brake switch (C) forward. The "PARKING BRAKE ON" light (D) should illuminate.

3-7

CONTROLS AND INSTRUMENTS FRAME SWAY CONTROL

& WARNING Always ensure that the machine level indicator (B) is at zero (0) degrees before raising the boom. Raising the boom with an unleveI machine may cause the machine to overturn, resulting in injury or death.

& WARNING Use the frame sway control to level the machine only when the boom angle indicator is at 0 degrees or less. Using the frame sway control when the angle indicator is more than 0 degrees may cause the machine to overturn, resulting in injury or death.

The frame sway control (A) is located on the forward side of the right arm rest. The frame sway control is used in conjunction with the machine level indicator (B) located in the center ofthe cross support that the interior rear view mirror is mounted on.

The sway control switch is either toggled to the left or right depending on the particular requirement.

3-8 ---"

..

--"-_._._-

------

GAUGES The following gauges are used to monitor the machine: 1 - Fuel Level o ______ .h1~_~

2 - Water Temperature, Engine 3 - Oil Pressure, Engine 4 - Oil Temperature, Powershift Transmission

o

5 - Oil Pressure, Powershift Transmission 6 - Voltmeter

HYDRAULIC PUMP DESTROKE BUTTON

it DANGER Depressing the pump destroke button while operating the machine will cause an ilmnediate loss ofhydraulic power, possibly creating a very dangerous situation. Hydraulic functions that will be affected are: FORK TILT, LIFT, BOOM EXTEND and RETRACT, PARKING BRAKE and SWAY. None of these functions will operate as long as the button is depressed. The service brakes will continue to function ifthe accumulator backup has a sufficient gas charge.

The pump destroke button (C) is the black push button switch located on the dash panel. o

For example, when starting the machine for the first tinle 011 a 30 degree F. day; depress the pump destroke button while starting the engine. Continue to depress the button for 15 to 20 seconds after the engine starts. Once the engine is running smoothly; release the button and the hydraulic pump will engage.

Depressing the pump destroke button will not be required for all other starts ofthe day; unless the engine has been allowed to cool completely.

c

3-9

CONTROLS AND INSTRUMENTS STEERING In addition to the steering wheel, the machine has another steering control, the steering selector switch.

A

The steering selector switch (A) is a three-position switch.

The three positions are: 4-wheel, 2-wheel , and oblique.

Switch positions are selected and function as follows:

4-'VHEEL

Handle rotatedforward

2--WHEEL

Handle directly centered

OBLIQUE (CRAB)

Handle rotated rearward

ffi CAUTION Before changing steering selections, make sure all four wheels are in line. Failure to align the wheels to the proper settings before changing steering positions may cause haphazard steering.

This mayresult in injury to personnel andlor damage to the machine or property.

TRANSMISSION The transmission control (B) has one lever that controls both directional and speed requirements. It is located on the left side ofthe steering column.

To shift into Forward gear gently pull the lever toward you and move the lever upward.

To shift into Neutral move the lever to the center position.

To shift into Reverse gear gently pull the lever toward you and move the lever downward.

To shift into a lower speed rotate the lever clockwise.

To shift into a higher speed rotate the lever counter-clockwise.

When shifting the transmission from forward to reverse while the machine is in motioll the transmission control (B) mnst be in 1st or 2nd gear only.

Forward lIst Forward I 2nd Forward/3rd

Low speed/High torque Medium speed/Medium torque High speed/Low torque 3-10

B

]

CONTROLS AND INSTRUMENTS FRONT AXLE DIFFERENTIAL LOCK· The front axle differential lock switch (C) is located near the operator's] eft foot. It is a standard featnre on all TH842C & TH844C models. The purpose for this device is to lock the front axle differential to gain added traction under certain conditions.

The front axle differential lock switch must be depressed and held in order to activate the axle differential lock. Re1easingthe switch disengages the axle differential lock.

Use this differential lock when you are unable to drive through certain types ofterrain such as sand, mud, snow, etc.

~WARNING Always bring the front tires to a complete stop before engaging the front axle differential lock.

Failure to stop the front tires before engaging the front axle differential lock mayresult in damage to the front axle.

Never steer the front tires while using the front axle differential lock.

Steering while the front axle differential lock is engaged may result in damage to the front axle.

3 -11

D

SECTION 4 OPERATION

4-1

TABLE OF CONTENTS

SECTION 4 - OPERATION

Operation And Safety Guidelines

4-3

Before Statting The Engine

4-4

Stmting The Engine

4-9

Before Operating The Forklift

4-11

TransportingALoad

4-15

Placing A Load

4-17

4-2

OPERATION OPERATION AND SAFETY GUIDELINES

it WARNING

Your safety and the safety ofthose around you depends upon you using care and judgement in the operation ofthis equipment. .Know the positions and functions of all controls before attempting to operate this machine. All equipment has limitations.

Understand the speed, braking, steering, stability, and load chart characteristics of this machine before operating. Read the Operator's Manual and ask questions ofyour supervisor until you kuow the machine's limitations. It is very important to read, fillly understand, and follow these operation and safety guidelines.

1. DO NOT operate this machine while people are under or near an elevated boom whether the boom is loaded or unloaded.

Falling objects from the forks or attachment may cause serious injury or death.

2. ALWAYS remain completely within the cab enclosure while operating this machine. Falling debris can cause serious personal injury or death.

3. NEVER extend a load beyond the load chart band. Machine tum over, component damage, injury or death could occur.

4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON 1HIS MACHINE OR ATTACHMENTS.

5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur.

6. INSPECT and clear the working area ofany obstructions (rocks, fence, wire, etc.) that could cause machine damage. If obstructions cannot be cleared, mark the obstructions with a stake or other marker that will be clearly visible to the operator.

7. DO NOT check the engine coolant level ifthe engine has recently been run. Injury could occur from escaping hot pressurized coolant.

8. ALWAYS wear the seat belt when operating this machine.

9. ALWAYS inspect the machine daily Check for leaks, worn hoses, loose belts, or anything out of the ordinary Repair andlor replace any worn, damaged or leaking parts immediately. Failure to do so can cause injury or death.

JO. CHECK to be sure that all guards and screens are secure and in their proper place.

11. CHECK to be sure that all safety devices such as parking brake, service brake, level gauge, neutral start safety switch, back-up alarm, and hom are fimctioning properly Always make sure mirror is adjusted properly 12. DO. NOT travel on terrain or in dangerous areas that could cause the machine to tip over.

13. DO NOT attempt to start the engine by towing or pushing. Damage to the powershift transmission could result.

14. CARRY A LOAD so that you have maximum machine stability and visibility is not obstructed.

15. ALWAYS level th e machine as indicated on the machine level indicator before raising boom. Raising the boom with an unlevel machine may cause the machine to overturn causing injury or death.

16. USE the frame sway control to level the machine only when the boom position is horizontal or lower. Using the frame sway control when the boom is higher than a horizontal position may cause the machine to overturn causing injury or death.

17. DO NOT depress the pump destroke button while operating the machine. This button should be used only during cold start ups. Depressing the button while operating the machine will cause an immediate loss ofhydraulic power that will affect fork tilt, lift, boom extend and retract, sway and all other hydraulic functions. Brakes will continue to function if the accumulator backup has a sufficient gas charge.

4-3

OPERATION BEFORE STARTING THE ENGINE

ffiWARNING DO NOT perform any procedures in this section, "BEFORE STARTING ENGINE", unless 1hemachine's engine is turned off and the parking brake is applied and the engine is cool. Failure to do so may result in serious injury, death or damage to the equipment.

Walk around the machine and check for any parts that are missing, wom, damaged, or leaking. Repair andJorreplace damaged parts.

CHECK ENGINE OIL LEVEL

John Deere Location:

Dipstick (A).

To Check:

The machine must be level.

Check when the engine is cold.

Remove the dipstick from the engine.

Oil should read between the add and the full marks.

Replace the dipstick.

NOTE:

Refer to page 5-24 of this manual for the proper oil specifications cmd capacities.

A

4-4

OPERATION BEFORE STARTING THE ENGINE

ffiWARNING DO NOT check the coolant level if the engine has been run recently Injury may occur from hot escaping pressurized coolant.

B

CHECK ENGINE COOLANT LEVEL Location:

Tank cap (B).

To Check:

Coolant should be visible in the top of the tank.

NOTE:

IF coolant needs to be added, fill with a 501.50 low silicate antifree~e mix (-34 degrees F) "itl! an approved nitrite or nitrite-mo1;ybdate based Supplemental Coolant Additive. This additive is required to prevent engine damage due to cylinder liner erusio/l and pitting. Do not use high-silicate automotive ailtiji-eeze or cooling system damage due to silicate dropout

eon occur.

Cortlact your local John Deere dealer for an approved antifreeze and Supplemental Coolant Additive.

OPEN WATER SEPARATOR

Location:

Water separator filter (C).

ThOpen:

Shut off the engine.

John Deere

Tum the valve on the bottom of the water separator filter counterclockwise.

Draill until clear fuel is present.

Retighten the valve.

NOTE.-

{r more than 2 oz. of fuel are drained, refilling of the filter is required to prevent hm'd starting. Refer to filter replacement on page .5-19 or this manual.

4-5

OPERATION BEFORE STARTING THE ENGINE

CHECK HYDRAULIC OIL LEVEL Location:

Sight glass (A). Behind the rear panel.

To Check:

Move th e machine to level ground.

A

Level the frame.

Completely retract the boom.

Position the forks level.

Lower the boom to the ground.

Oil should be visible 112 way in the sight glass.

NOTE:

Refer to page 5-]4 of this manual for the proper oil specifications and capacities.

INSPECT AIR CLEANER Location:

Air cleaner assembly.

To Check:

Remove the rear ofthe canister, remove the elements.

Guideline:

Inspect the filter elements for contamination.

Inspect the tubing going to the filter body from the engine for cracks or leaks. Inspect the air cleaner body and gaskets for cracks or leaks.

it WARNING Duc to various operating conditions, the air cleaner's elements should be changed as often as the environment reqUITes.

4-6

OPERATION BEFORE STARTING THE ENGINE

CHECK TRANSMISSION OlLLEVEL ,

Location:

Dipstick (B)

To Check:

Level the machine.

B

Place the transmission control in neutral.

Set the parking brake.

The engine must be nllll1ing to check.

Bring the transmission oil temperature to a minimum of180 degrees F.

j

Remove the dipstick. The oil level should be between the add and full marks.

---

Replace the dipstick.

NOTE:

Refer to page 5-24 of this manual for the proper oil specifications and capacities.

ffiWARNING Serious personal injury can result from a loose or damaged fan.

Never pry on a fan because this may cause fan damage and/or failure.

CHECK ENGINE FAN

To Check:

Visually inspect the cooling fan (C) for cracks, loose bolts, bent or loose blades etc.

c

4-7

OPERATION BEFORE STARTING THE ENGINE

CHECK TIRE FOR PROPER INFLATION

Location:

Wheel ends.

To Cbeck:

Check the tire pressure with the tire cold and a properly functioning air pressure gauge. Position the valve stem (A) to the top ofthe tire.

Setting:

50 PSI.

~DANGER All tires require a calcium chloride ballast or an optional foam filling to be operated safely. The loss of ballast can affect machine stability and cause a rollover hazard resulting in damage, injury or death.

A

4-8

STARTING THE ENGINE

ffi DANGER Anyproblems discovered in the steps prior to "BEFORE STARTING THE ENGINE" should be corrected before the machine is started.

& DANGER NEVER attempt to start the machine without being seated in the operator's compartment, the parking brake switch (B) toggJed forward in the on position and the transmission control (C) in the neutral position. Attempting to start the machine from outside the operator's compartment may result in property damage, serious injury or death.

& DANGER If the machine should start with the transmission control lever (C) in gear, stop operation at once or property damage, serious illjuryor death may occur. Have a qualified service technician repair the machine.

{used the ignition key in the ignition switch (D). Rotate the key clockwise until the engine starts. Release the key when the engine starts.

4-9

OPERATION STARTING THE ENGINE

& CAUTION Iftbe engine fails to start within 30 seconds release the key, wait at least 2 minutes to allow the starter motor to cool before trying again. Ifthe engine fails to start after four attempts, trouble shoot and correct the problem. DO NOT turn the key if the engine is running. This may cause damage to the starter motor.

ffiCAUTION Attempting to start the engine by towing or pushing the machine will result in damage to the powershift transmission and will not start the engine! It also is an unsafe practice that could cause personal injury.

4-10

BEFORE OPERATING THE FORKLIFT

& CAUTION If any gauge reading does not fall within the set tolerances the machine must be repaired before operation.

Check the dash mounted gauges for logical readings.

(1)

Fuel Level

112 to Full

(2)

Engine Water Temperature

180°F to 200°F

(3)

Engine Oil Pressure

40t080 PSI

(4)

Transmission Oil Temperature

180°Fto 200°F

(5)

Transmission Oil Pressure

240 to 280 PSI

(6)

Voltmeter

12 to 14 Volts

STANDARD JOYSTICK FUNCTIONS

Operate the joystick controller momentarily in all directions.

H,t/E A

o ...

.... C

~IJ!"'G

A -Boom Down B - Boom Up C - Boom Out D-Boom Tn E - Room Down and Out F - Boom Up and III G - Boom Up alld Out H - Boom Down and In

BUTTON DEPRESSED FUNCTIONS

A

t

[8!

4-11

A - Tilt Forward B - IIlt Back

OPERATION BEFORE OPERATING THE FORKLIFT

Operate the frame sway control (A) momentarily right and left.

c

Check the steering operation by turning the steering wheel (B) approximately 114 tum in each direction. Ifth e front and rear tires are not aligned properly, straighten the rear wheels with tbe steering selector valve (C) in the "4 wheel" position. Move the steering selector valve to tbe "2 wheel" position. Bring the front tires into alignment with the rear tires. Place the steering selector valve back into the "4 wheel" position.

4-12

OPERATION BEFORE OPERATING THE FORKLIFT

& DANGER Any problems with the service brakes or the parking brake found while conducting the daily inspection should be corrected immediately. Failure to do so could result in injury or death.

D

Activate the transmission using the transmission control lever CD). As soon as the machine starts to move, apply the service brake pedal. The machine should stop immediately.

Apply the parking brake by toggling the parking brake switch (E) forward. The "PARKING BRAKE ON" light (F) should illuminate. The machine should not be able to be driven with the parking brake in the forward! on position. Release the parking brake by toggling the parking brake switch rearward.

4-13

J

OPERATION BEFORE OPERATING THE FORKLIFT

& DANGER Never operate themachmewith a faulty backup alarm. Doing so may result in serious injury or death.

A

Place the transmission control lever (A) in reverse. The backup alarm should sound. If it does not sOlllld, have the backup alarm repaired inunediately.

B

Check and adjust both the interior rear view mirror (B) and the exterior right hand mirror (C) ifrequired.

4-14

[

OPERATION TRANSPORTING A LOAD

& WARNING Transporting a load with the boom extended and the boom angle indicator arrow (D) reading more than 0 degrees could cause aroll over hazard.

& WARNING At no time should any load be suspended from the forks by use of chains, ropes, straps etc. If a load must be suspended the use of a truss (jib) boom is mandatory. Proper rigging procedures should always be followed.

The forks should always be tilted back slightly during transportation to ensure stability ofthe load.

D

The load should be kept as low to the ground as possible while traveling. Always move a loaded machine with the boom angle indicator CD) at 0 degrees or less.

4-15

TRANSPORTING A LOAD

A

LLWARNING Slower speeds should be used whenever transporting a load.

Always bring the machine to a complete stop before reversing the transmission control lever (A). Failure to do so can result in damage to the load, the machine andlor bystanders.

'----------0\

;-----'1

J

-"-''''---~

Always keep the boom retracted to ensure greater stability

Always place the load in the center and completely against the back oftile fork frame. By doing so greater stability will result.

IMPORTANT: Never attempt to use tile forks andlor attachments for prying wedged or frozen loads free. Damage to the load, palletandlor machine could result.

4-16

PLACING A LOAD

D

ffi WARNING Do not sway the machine with the boom angle indicator arrow (B) at more than 0 degrees. By doing so you could cause a roll over hazard which may result in injury or death.

ffi DANGER Always apply the parking brake by toggling the parking brake switch (el forward before lifting and/or placing a load. Failure to do so could allow the machine to roll over which may res:ult in injury or death.

it CAUTION Always bring the machine to a complete stop before applying the parking brake (C). Failureto do so will damage the parking brake disc packs, which mayvoid the axle warranty.

c

Before placing a load, the frame should be leveled. This can be done by the use of the switch labeled sway control CD) located on the forward side ofthe right arm rest. The frame sway control is used in conjunction with the machine level indicator (E) located in the center of the cross support that the interior rear view mirror is mounted on. The sway control switch is either toggled left or right depending on theparticular requirement. Adjust the sway control (D) until the indicator ball 011 the level gauge (E) is on the 0 degree mark.

ffiWARNING Always ensure that the machine level indicator (E) is at zero (0) degrees before raising the boom. Raising the boom with an unleve1 machinemay cause the machine to overturn, resulting in injury or death.

ffiWARNING Use the frame sway control to level the machine only when the boom angle indicator (B) is at 0 degrees or less. Using the frame sway control when the angle indicator is more than 0 degrees may cause the machine to overturn, resulting in injury or death.

4-17

OPERATION PLACING A LOAD A

& DANGER Traveling with a reading of more than 0 degress on the boom angle indicator arrow (A) may cause a rollover hazard.

Gradually move the 4-way controller towards the letter (B) to lift the load vertically. Hold the controller back until the required height has been achieved.

c

Gradually move the 4-way controller towards the letter (E) to bring the load DOWN and OUT into final position. Lower the load until the weight is completely offthe forks.

F~

1

Gradually move the 4-way controller towards the letter (F) to bring the boom UP and IN. This will bring the forks out of the load. Once the forks are clear of the load the boom can be lowered.

4-18

OPERATION PLACING A LOAD

TH644C, TH842C, TH844C ONLY! When placing a load with the Model TH644C, TH842C, or the TH844C the rear axle stabilizing cylinders need to be taken into consideration. When the boom reaches an angle of 60 DEGREES, all frame leveling and transmission functions are disabled and the rear axle stabilizing cylinders become locked.

TIlls DOES NOT affect any boom or fork functions. To unlock the rear axle stabilizing cylinders and enable the transmission functions, lower the bOOlTI to a position less than 60 degrees.

4-19

SECTION 5 MAINTENANCE PROCEDURES

5-1

TABLE OF CONTENTS

SECTION 5 - MAINTENANCE PROCEDURES

General Safety Practices

5-3

Service Intervals

5-5

Required Grease Intervals

5-6

Grease Fitting Locations

5-7

Daily Maintenance Procedures

5-8

50 Hour Maintenance Procedures

5-12

100 Hour Maintenance Procedures

5-15

250 Hour Maintenance Procedures

5-17

500 Hour Maintenance Procedures

5-18

750 Hour Maintenance Procedures

5-20

1000 Hour Maintenance Procedures

5-2]

2000 Hour Maintenance Procedures

5-23

Filter Guide

5-24

Recommended Fluids And Capacities

5-24

Hydraulic Pressure Settings

5-25 5-2

GENERAL SAFETY PRACTICES

BEFORE SERVICING Read the entire Maintenance Procedure Section.

Familiarize yourselfwith all the safety precautions listed in Sections 1 & 2.

Pay close attention to all the safety alert symbols.

Be sure you understand the procedures detailed in this section.

Wear personal protective equipment.

Remove rings and jewelry Move the machine to a safe level work place.

Lower the boom and support all raised equipment.

Shut down the machine.

Remove the key from the ignition.

Be carefhlnot to spill fuels and lubricants.

Do not fill or refuel the fuel tank while the engine is running or hot. Doing so could cause a fire and/or an explosion.

Do not smoke while refueling or working with fuel to avoid a fire and/or explosion.

IMPORTANT! Always clean up spilled fuel and/or lubricants to avoid polluting the earth.

5-3

MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES

HYDRAULIC SAFETY

ffi WARNING Hot hydraulic oil can cause severe burns. DO NOT work on the hydraulic system if the oil system temperature exceeds 120 degrees F. (49 degrees C.) Before ANYONE works on the hydraulic system: 1. Lower the boom to the horizontal position.

2. Support the boom to avoid unintentional lowering.

3. Shutdown the engine.

4. Removethekeyfrolll the ignition.

5. Clean the area around the oil reservoir cap (A).

FLUID UNDER PRESSURE

ffi WARNING Escaping fluid under pressure can penetrate the skin and can cause serious personal injury Use a piece of cardboard or paper to search for leaks.

DO NOT use hands! Before disconnecting hydraulic lines, be sure to relieve all line pressure. Before applying pressure to the system, be sure that all connections are tight. DO NOT apply pressure to a damaged line, hose or fitting.

Ifinjured by escaping fluid, see a doctor at once. Proper medical treatment must be administered immediately A serious infection or reaction can result without proper medical trcatment.

WELDING PRECAUTIONS

ffi WARNING DO NOT weld on any structurallllember. Anymlauthorized welding can cause structural failure or possible personal injury All unauthorized welding or repair procedures will void thelllachine warranty.

Before performing any authorized welding, be sure to disconnect the positive lead from the battery. Properly attach the ground cable ofthe welder to the frame member that is being welded. Failure to do so can cause electrical system damage.

5-4

MAINTENANCE PROCEDURES SERVICE INTERVALS DAlLY CIIEC-X ENGINE OIL CIlEeX COOLANT LEVEL CHANGE HYDRAULIC RETURN FILTERELEMENT

50Hrs.

• •

lOOHrs.

250Hrs.

•

.* .*

CHANGE ENGINE OIL & FILTER

500 Hrs.

750 Hrs.

•

INSPEcr ALTERNATOR BELT ENGINE VALVE ADJUSTMENT CHANGE DIFFERENTIAL OIL (AXLE)

.*

• •

REPLACE FUEL FILTERS COOLANT CONC'ENTRATION CfIECK ENGINE FAN OPENVVATERSEPERATOR CIIECK TIRE INFLATION FLUSH AND PRESSURE TEST COOLING SYSTEM CHECK TRANSMISSION OIL REPLACE TRANSMISSION OIL& FILTER

• • •

•

CHANGE PLANETARY REDUCI"ION OIL (AXLE}

ClIECK HYDRAULIC OIL LEVEL CllECK HYDRAULIC RETURN FILTERELEMENT

• •

2000Hrs.

.***

• .*

•

CIIECKAXLE OIL LEVELS

INSPECT AIR CLEANER AND AIR CLEANER SYSTEM

•

1000Hrs.

•

.**

•

.*

• • •

For procedures to perform tlte above listed items turn to tlte following pages: 5-8 thru 5-23.

* For initial break-in period only

** For initiall 00 hours only.

** * John Deere engines require valve adjustment every 2000 hours only.

5-5

MAINTENANCE PROCEDURES REQUIRED GREASE INTERVALS

LOCATION

DAILY

50Hrs.

• •

SMALL BOOM ROLLERS (4) BASE END TILT CYLINDER HEAD END TILT CYLINDER rORK FRAME PIVOT PIN (2) HEAD END LIFT CYUNDER (2) BASE END LIFT CYLINDER (2)

• • • •

• •

!'RONT DRIVERHAFT (3) REAR DRIVESHAFT (3) BASE END SWAY CYLINDER (2) HEAD END SWAY CYLINDER (2) BOOM PIVOT (2)

• • •

• • • • •

REAR AXLE TRUNIONS (4) FRONT AXLE TRUNIONS (4) FRONT AXLE PIVOT (2) REAR AXLE PIVOT (2) MIDDLE BOOM ROLLERS (4) S,'UlE END REAR LOCK UP CYLINDER (2) 644C-842C·844C ONLY HEAD END REAR LOCK UP CYLINDER (2) 644C-842C-844C ONLY

250Hrs

• •

5-6

500Hrs.

MAINTENANCE PROCEDURES GREASE FITTING LOCATIONS TH636C GREASE WITII BOOM. FULLY EXTIlNDBD I WCATION

, 2

1

1

1

1 1

1

TH644C & TH842C & TH844C GREASB WITH BOOM. FULLY EXTENDED I LOCATION OF lARGE BOOM GREASE pOlNIS SHOWN I MIDDLE _BOOM GREASE POINTS SIMll.ARLOCATION I TYPICAL

~

,'f~~~ I

1

1

1

.

1

1

5-7

1

1

I

I

1

1

bAlLY MAINTENANCE

Perfonn "BEFORE SERVICING PROCEDURES" before attempting any ofthe following checks.

Perform "BEFORE OPERATING CHECKS" before attempting any ofthe following checks.

John Deere CHECI( ENGINE OIL LEVEL

Location:

Dipstick (A).

ToCbeck:

The machine must be level.

A

Check when the engine is cold.

Remove the dipstick from the engine.

The oil level should be between the add and full marks.

Replace the dipstick.

NOTE

Refer to page 5-24 of this manual.for the proper oil specifications and capacities.

it WARNING Do not check the coolant level if the engine has recently been run. Injury may occur from hot escaping pressurized coolant.

CHECK ENGINE COOLANT LEVEL

Location:

Radiator cap (B).

To Check:

Coolant should be visible in the top of the tank.

NOTE:

If coolant needs to be added, fill with a 50150 low silicate antiji'eeze mix (-34 degrees F) with an approved nitrite DI' nitrite-molybdate based Supplemental Coolant Additive. This additive is required to prevent engine damage due to cylinder liner erosion and pitting. Do not use high-silicate automotive antifreeze or cooling system damage due to silicate dropout can occur Contact your local .1ohn Deel'e dealer /01' an approved antiji'eeze and Supplemental Coolant Additive.

5-8

B

MAINTENANCE PROCEDURES

D

DAILY MAINTENANCE

& WARNING Serious personal injury can result from a loose or damaged fan.

N ever pry 011 a fan because this may cause fan damage and!or failure.

CHECKENGINE FAN

To Check:

Visually inspect the cooling fan (C) for cracks, loose bolts, bent or loose blades, etc.

John Deere OPEN WATER SEPARATOR

Location:

Water separator filter (D).

To Open:

Shut off the engine.

Turn the valve on the bottom of the filter counterclockwise.

D Drain until clear fuel is present.

Retighten the valve.

NOTK

(f more than 2 oz. of filel are drained. refilling of the Flter is required to prevent hard starting. Refer to Flte/' replacement on page 5-19 (~f this manual.

5-9

]

MAINTENANCE PROCEDURES DAlLY MAINTENANCE

CHECK TRANSMISSION OIL LEVEL Location:

Dipstick (A)

To Check:

Level the machine.

A

Place the transmission control in neutral.

Set the parking brake.

The engine must be running to check.

Bring the transmission oil temperature to a minimum of1S0 degrees F. Remove the dipstick. The oil level should be between the add and full marks.

Replace the dipstick.

NOTE.

Refer to page 5-24 of this manual for the proper oil specificatiolls and capacities.

CHECK HYDRAULIC OlLLEVEL Location:

Sight glass (B). Behind the rear panel.

To Check:

Move the machine to level ground.

Level the frame.

B

Completely retract the boom.

Position the forks level.

Lower the boom to the ground.

Oil should be visible 1/2 way in sight glass (B).

NOTE.

Refer to page 5-24 of this manual for the proper oil specifications and capacities.

5-10

MAINTENANCE PROCEDURES DAILY MAINTENANCE

CHECK TIRE FOR PROPER INFLATION

Location:

Wheel ends.

To Check:

With the valve stem (C) positioned to the top of the tire, check the tire pressure with the tire cold and a properly functioning air pressure gauge.

Setting:

50 PSI.

c

& DANGER All tires require a calcium chloride ballast or an optional foam fill to be operated safely. The loss of ballast can affect the machine's stability and cause a rollover hazard, resulting in damage, injury or death.

INSPECT AIR CLEANER

Location:

Air cleaner assembly.

To Check:

Remove the rear ofthe canister, remove the fIlter elements.

Guideline:

Inspect the filter elements for contamination.

Inspect the tubing going to the filter body from the engine for cracks or leaks. Inspect the air cleaner body and gaskets for cracks or leaks.

ffi WARNING Due to various operating conditions, the air cleaner's elements should be changed as the environment requires.

5-11

PROCEDURES

MAINT

NCE

50

CODllPleteall "DAILYMAINTENANCE" time interval. attempting

CHECK HYDRAULICRETURNFILTER GAUGE Location:

Return filter gauge (A). Located behind the left hand side screen, on top of the oil reservoir and on the left hand side ofthe return filter (B).

To Check:

Raise the boom to the horizontal nO:Sltlon. hoo,m CvI1TIder fully. to full RPM. ~vl'lnt1j~T at full The return filter gau than 25 PSI. Ifthe ...

"",.."t ... _ _

should not read more is more than 25 PSI, the

fih~ekmemmu~becrum2:ed.

CHANGE HYDRAULICRETURNFILTER ELEMENT Location:

The return filter element is located inside the return filter (B) on top ofthe oil reservoir.

To Change: Retract the boom and lower the forks to the ground.

Shut off the Release the pressure in the oil reservoir by the filler / breather cap (D).

D

F

& CAUTION The return filter cover is loaded. but do not remove, the four cover bolts (E) on the ofthe return filter asslemlJly. Cal~enlUV down and rotate the cover clockwise to remove~ Remove the cover and pull the filter element out the swiv ndle on the element. Make sure both are in inside the new filter elelneIlt, then transfer valve into the new filter element. Re· 11 the filter elelneIlt.. and cover, . g sure the between the cover and the return filter ass ,emlbly. ,JI"J'-',"'..."".....L'l

NOTE:

This change interval is only for the first initial 50 hours of use. Following initial replacement offilter Service Intervals on page 5-5 of this manual for standard change intervals.

5-12

c

MAINTENANCE PROCEDURES 50 HOUR MAINTENANCE

CHANGE TRANSMISSION OIL AND FILTER Location:

To Change:

G

Transmission filter (G).

Drain plug (H).

Dipstick (1).

I

Bring the transmission oil temperature to a minimum of 180 degrees F. Remove the drain plug.

Allow the oil to drain completely into a proper collection container.

Clean the area around the filter thoroughly.

Remove the transmission filter.

Apply a thin :fi.hn of clean transmission oil to the new filter gasket surface and install the filter according to the manufacturer's specifications.

Install the drain plug.

Fill the transmission through the dipstick tube (I) until the oil level is between the add and full marks.

Run the engine for a minimum of 2 minutes at engine idle.

Check the oil level at the dipstick.

Raise the transmission oil temperature to a minimum of 180 degrees F. Recheck the oil at the dipstick.

NOTE'

This change inte,11al is on~y for the first initial 50 hours of use. Following the initial replacement of oil and filter see the Sel11ice intef11als ort page 5-5 of this manual for the standard change interval.

}I/OTE

Refer to page 5-24 of this manual.for the proper oil spec?fications and capacities.

5 -13

MAINTENANCE PROCEDURES 50 HOUR MAINTENANCE

CHECKAXLE PLANETARYOIL

Loc.'ltion:

Filler/drain plug (A).

To Check:

Always check the lubricant level in the wheel end wit.h the filler/drain plug at the 3 or 9 o'clock position.

Remove the filler/drain plug.

Oil should flow freely from the hole.

Replace the filler/drain plug.

NOTE.

Refer lu page 5-24 af this manual.for the proper ail sper:ificaliolls and capacities

A

CHECK AXLE DIFFERENTIAL OIL

Location:

Fill plug (B).

Check plug (D).

Drain pI ug (C).

To Check:

Move the machine to level ground.

RClllovetbe check plug. Oil should flowfrccly lJ-om the hole.

Replace the check plug.

B NOTE.

Nefer to page 5-24 ollhis manual for Ihe proper oil speciji"cations and capacities.

5 - 14

c

D

MAINTENANCE PROCEDURES 100 HOUR MAINTENANCE

Pcrfurm "BEFORE SERYrCING PROCEDURES" before attempting any ofthe following checks.

Complete aU "DAILYMAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

Perfonn "BEFORE OPERATING CHECKS" before attempting any ofthe following checks.

CHANGE AXLE DIFFERENTIAL OIL

Location:

Fill plug (B).

Check plug CD).

Drain plug (C).

To Change: Remove the drain plug.

Loosen the fill plug to allow the oil to drain completely into a proper collection container.

Replace the drain plug.

Remove the check plug and the fill plug.

Fill with oil through the fill plug hole until it flows freely from the check plug 1101e.

Replace the check plug and the fill plug. lIfO FE'

'!'ltis lim~ intelwd is fOI' Ihe first ilJitial 100 hours. Refer to pllge 5-5 of this manual for additional service InteI1 I ai:;.

NOTE

Refet· 10 page 5-24 of this manual for the propet· oil spel'ijialtiolls o/ld capacities.

B

5 -15

c

D

MAINTENANCE PROCEDURES 100 HOUR MAINTENANCE

CHANGEAXLEPLANETARYEND OIL Location:

Filler/drain plug (A).

To Change: Rotate the wheel end until the filler/drain plug is at the lowest point of the wheel end.

Remove the filler/drain plug and allow the oil to drain completely into a proper collection container.

Rotate the wheel end until the filler/drain plug hole is at the 3 or 9 o'clock position.

Fill with oil until it flows freely from the filler/ drain plug hole.

A

Replace the filler/drain plug (A).

NOTE.

This time interval is for the first initial 100 hours. Refel' to page 5-5 of this manual for additional service intervals.

NOTE.

Refer to p(fge 5-24 of this manual for the proper oil speciflcatirms and capacities.

CHANGE TRANSMISSION OIL AND FILTER To Change: Refer to the procedure listed on page 5-13 of this manual.

NOTE.

'This time intelval is for the first initial 100 hours. Refer to page 5-5 of this manual for additional sefvice intervals.

5 -16

250 HOUR MAINTENANCE

Pelform "BEFORE SERVICING PROCEDURES" before attempting any of the following checks.

Complete all "DAILY MAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "100 HOUR MAINTENANCE" checks plior to this time interval.

Perform "BEFORE OPERATING CHECKS" before attempting any of the following checks.

E

B

CHANGE HYDRA UUC RETURN FILTER ELEMENT

Location:

The return filter element (C) is located inside the retum filter assembly (B) on top of the oil reservoir.

To Change: Retract the boom and lower the forks to the ground.

Shut off the engine. Release the pressure in the oil reservoir by loosening the filler / breather cap (D).

D

F

& CAUTION The retum filter assembly cover is spring loaded.

Loosen, but do not remove, the four cover bolts (E) on the top ofthe retum filter assembly. Carefully push down and rotate the cover clockwise to remove.

Remove the cover spring and pull the filter element out using the swivel handle on the element. Make sure both a-rings are in place inside the new filter element, then transfer the bypass valve (F) into the new filter element. Reinstall the filter element, cover spring and cover, making sure the a-ring is in place between the cover and the retum filter assembly.

5-17

c

MAINTENANCE PROCEDURES 500 HOUR MAINTENANCE

CHANGE ENGINE OIL AND FILTER Location:

Oil filter (A).

Drain plug (B).

FiIlcap (C).

To Change: Operate the engine until the engine water temperature has reached 140 degrees F. Turn the engine off Remove the drain plug (B).

Allow the oil to drain completely into a proper collection container.

Clean the area thoroughly around the filter area.

Remove the engine oil filter.

Apply a thin film ofclean engine oil to the new oil filter gasket surface.

Fill the oil filter with clean engine oil before installation.

Install the oil filter to the manufacturer's specifications.

Clean the surface around the drain plug.

Install the drain plug.

Fill the engine with the proper oil through the oil fill cap until the oil level is between the add and the full marks on the dipstick.

RUll the engine for a minimum of2minutes at engine idle.

Turn the engine off Once the engine has cooled recheck the oil level at the dipstick.

NOTE.

Refer to page 5-24 of this manual for the proper oil spec~ficalions and capacities.

5-18

John Deere

MAINTENANCE PROCEDURES 500 HOUR MAINTENANCE

Perform "BEFORE SERVICING PROCEDURES" before attempting any of the following checks.

Complete all "DAILY MAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

C~mpleteall "100 HOUR MAINTENANCE" checks prior to this time interval.

Completeall "250 HOUR MAINTENANCE" checks prior to this time interval.

Perfonll "BEFORE OPERATING CHECKS" before attempting any ofthe following checks.

REPLACE FUEL FILTERS

Location:

Filter (D).

Water separator (E).

John Deere

To Change: Wipe all the dirt from the area surrounding the filter( s).

Remove the filter( s). Thoroughly clean the gasket sealing surface after filter removal.

Fill the new filter(s) with fuel. lnstall the newfilter(s).

Install the filter( s) according to the filter manufacturer's specifications.

NOTE:

John Deere engines only have one filter element. It is used as a filter alld water separator.

5-19

D&E

MAINTENANCE PROCEDURES 500 HOUR MAINTENANCE A CHECK COOLANT CONCENTRATION Location:

Radiator cap (A).

To Check:

Remove the radiator cap.

Factory recommended coolant concentration is a 50/50 mixture oflow silicate antifreeze (-34 degrees F. ) with an approved nitrite or nitrite-molybdate based Supplemental Coolant Additive. This additive is required to prevent engine damage due to cylinder liner erosion and pitting. Do not use high-silicate automotive antifreeze or cooling system damage due to silicate dropout can occur.

Contact your local John Deere dealer for an approved antifreeze and Supplemental Coolant Additive.

750 HOUR MAINTENANCE Perionn "BEFORE SERVICING PROCEDURES" before attempting any ofthe following checks.

Complete all "DAlLYMAlNTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "100 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "250 HOUR MAINTENANCE" checks prior to this time intervaL Complete all "500 HOUR MAINTENANCE" checks prior to this time interval.

Perform "BEFORE OPERATING CHECKS" before attempting any oftlle following checks.

CHANGE AXLE OILS To Change: Refer to the procedures listed on pages 5-15 & 5-16 ofthis manual.

5 -20

MAINTENANCE PROCEDURES 1000 HOUR MAINTENANCE

Perfonn "BEFORE SERVICING PROCEDURES"before attempting any oftIle following checks.

Completeall "DAlLY MAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

Completeall "100 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "250 HOUR MAINTENANCE" checks prior to this time interval.

Completeall "500 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "750 HOUR MAINTENANCE" checks prior to this time interval.

Perform "BEFORE OPERATING CHECKS" before attempting any of the following checks.

MANUFACTURER ENGINE MANUALSAREAVAILABLE FROM YOUR LOCAL TEREXHANDLERDEALER.

ADJUST ENGINE VALVES To Adjust:

See engine manual for procedure.

CHECK FAN BELT TENSION To Check:

See engine manual for procedure.

CHECK FAN BELT CONDITION To Check:

See engine manual for procedure.

CHANGE TRANSMISSION OIL AND FILTER To Change: Refer to procedure listed on page 5-13 ofthis

manual.

5-21

1000 HOUR MAINTENANCE

ADJUST EXTENSION-RETRACTION CHAINS TO CHECK: Raise the boom to the horizontal position. The proper adjustment can be checked with a tape measure. Extend the boom fully, then retract the boom about one inch. On either side ofthe middle boom section estimate the center. Place one end ofthe tape measure on the top surface of the boom directly above the estimated center.

~

c.

~

010 010 010 oXo oXo

ox " o 0'10 oXo oxo oYo oyo 0 0 OJO c:>!o OJ, N

-

\ TOLERANCE: The measurement from the top surface ofthe boom to the lowest part of the extension chain should be no less than 2 3/8 inches.

~ MIDDLE BOOM MIDPOINT

TO ADJUST: Ifthemeasurement is less than 2 3/8 inches, tighten the chain anchor (A), which is located on the top, front ofthe large boom tllbe, as follows: A. Tighten an adjustable wrench across the flat part ofthe chainjust ahead ofthe chain anchor (A).

B. With a 1 7/16 inch wrench tighten the one inch nutto collapse the spring. Continue to tighten until the chain is in toierance.

C. With a feeler gauge check the gap between the spring (B).

The gap should be no less than .030. The spring coils should never be collapsed completely.

B

5-22

A

MAINTENANCE PROCEDURES 2000 HOUR MAINTENANCE

Perfuilll"BEFORE SERVICJNG PROCEDURES" before attempting any ofthe following checks.

Completeall "DAILYMAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

Completeall "100 HOURMAINTENANCE" checks prior to this time interval.

Completeall "250 HOUR MAINTENANCE" checks prior to this time :interval.

Complete all "500 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "750 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "1000 HOUR MAINTENANCE" checks prior to this time interval.

Perfoilll "BEFORE OPERATING CHECKS" before attempting any ofthe following checks.

FLUSH AND PRESSURE TEST COOLlNGSYSTEM To Test:

See engine manual for procedure.

5-23

MAINTENANCE PROCEDURES FILTER GUIDE FILTER

PART NO.

Engine Oil Filter / John Deere

7-183-184

Transmission Oil Filter

7-126-349

Hydraulic Oil Reservoir Return Filter Element

7-118-02

Engine Air Cleaner Element/Primary

7-109-04

Engine Air Cleaner Element/ Safety

7-109-14

Engine Fuel Filter / John Deere

7-183-45

Filler-Breather (Hydraulic Oil Reservoir)

7-272-11

RECOMMENDED FLUIDS AND CAPACITIES DESCRIPTION

CAPACITY

'IYPE

Engine OUI John Deere

14 Quarts

Refer to John Deere engine manual

Transmission Oil

13.6 Quarts

Chevron RPM SAE lOW

Axles DiJIereotial Planet Ends

9 Quarts

1 Quart (Each End)

Chevron Supreme 80W90 LS Chevron Supreme 80W90 LS

Hydraulic Oil Reservoir

34 Gallons

Chevron AW 46

Hydraulic System

50 Gallons

Chevron AW 46

Fuel Tank

30 Gallons

# 2 Diesel Fuel

NOTE: Fluid levels may vary slightlyfrom machine to machine sofluid levels should always be checked manually.

5-24

HYDRAULIC PRESSURE SETTINGS

GA UGE PORT 1 (G1) MAIN PUMP PRESSURE Location: Test port 1 (A). Behind the right hand rear side screen.

Hydraulic pump (B). Under the transmission cover.

Adjuster (C). On the hydraulic pump.

To Check: Attach a pressure gauge to test port 1 (A). Start the engine. Do not operate any controls. The pressure reading should be as follows: TH636C TH644C TH842C TH844C

2800 PSI 3000 PSI 3000 PSI 3000 PSI

ToAd.iust: Remove the acom nut from the adjuster (C). Loosen the jam nut and tum the allen head adjusting screw clockwise to increase the pressure and counterclockwise to decrease the pressure. Retighten the jam nut. Replace the acom nut.

B

GAUGEPORT 1 (G1) SERVICE BRAKE ACCUMULATOR Location: Test port 1 (A). Behind the right hand rear side screen.

To Check: Attach a pressure gauge to test pOli 1 (A). Start the engine. Do not operate any controls. Apply and release the service brakes a few times. With the service brakes released, shut down the engine.

The pressure reading should be as follows: TH636C TH644C TH842C TH844C

2800 PSI 3000 PSI 3000 PSI 3000 PSI

A ToAdjust: Not adjustable. Ifthe pressure drops below 2000

PSI after a period oftwo minutes, troubleshoot the brake circuit.

5 -25

c

HYDRAULIC PRESSURE SETTINGS GAUGE PORT 2 (G2) STEERING SYSTEM PRESSURE Location: Test port 2 (A). Behind the right hand rear side screen.

Control block (B). On the front face ofthe oil reservoir.

Cartridge (C). On the control block.

To Check: Attach a pressure gauge to test port 2 (A). Start the

engine. Do not operate any controls. The pressure reading should be as follows: TH636C TH644C TH842C TH844C

2250 PSI 2250 PSI 2250 PSI 2250 PSI

ToAdjust: Loosen the jam nut on the steering cartridge (C) and turn the allen head adjusting screw

clockwise to increase the pressure and counterclockwise to decrease the pressure.

Retighten the jam nut.

E GA UGE PORT 3 (G3) CONTROL (PILOT) PRESSURE Location: Test port 3 (D). Behind the right hand rear side screen.

Control block (B). On the front face of the oil reservoir.

Cartridge (E). On the control block.

To CheclG Attach a pressure gauge to test port 3 (D). Stali the

engine. Do not operate any controls. The pressure reading should be as follows: TH636C TH644C TH842C TH844C

500 PSI 500 PSI 500 PSI 500 PSI

ToAdjust: Loosen the jam nut on the controller cartridge (E)

and turn the allen head adjusting screw clockwise to increase the pressure and counterclockwise to decrease the pressure. Retighten the jaml1ut.

5-26

B

MAINTENANCE PROCEDURES HYDRAULIC PRESSURE SETTINGS

GAUGE PORT 4 (G4) TILT LIMITER PRESSURE Location: Test port 4 (F). Behind the right hand rear side screen.

Tilt Limiter Block (H). On the front of the oil reservoir.

Cartridge (I). On the Tilt Limiter Block.

To Check: Attach a pressure gauge to test port 4 (F). Start the engine. Completely collapse the fork tilt cylinder and hold in a dead head position. (The tilt cylinder must be collapsed completely and dead headed to get a pressure reading). The pressure reacting should be as follows: TH636C TH644C TH842C TH844C

1200 PSI 1200 PSI 1200 PSI 1200 PSI

ToAdjust: Loosen the jam nut on the tilt limiter cartridge (1) and turn the allen head adjusting screw clockwise to increase the pressure and counterclockwise to decrease the pressure. Retighten the jam nut.

5 -27

F

SECTION 6 MATERIAL SAFETY DATA

6-1

TABLE OF CONTENTS

SECTION 6 - MATERIAL SAFETY DATA

Material Safety Data Sheets

6-3

Califomia Proposition 65 Warnings

6-4

6-2

MATERIAL SAFETY DATA SHEETS (MSDS)

The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 ctr 1910.1200, and in some cases state and local Right-To-Know laws, may require specific MSDS be available to employees plior to operating this equipment. This may include information on substances contained in the equipment such as antifi-eeze, brake fluid, battery acid and hydraulic fluid.

TEREX HANDLERS will provide, at no cost, Material Safety Data Sheets which are applicable to their product line. Simply request them fi-om your local TEREX HANDLER dealer or contact us at: TEREX HANDLERS P.O. Box 790

Baraga, MI 49908-0790 To ensure a prompt response, please be sure to include your retu111 address and zip code, along with the machine model and selial number.

6-3

MATERIAL SAFETY DATA CALIFORNIA PROPOSITION 65 WARNINGS

The following warnings are required on all offroad equipment operating in the State ofCalifomia. Ifyou are operating a TEREX HANDLER in the State of Califomi a and do not see the approved warning labels, please contact us for a replacement at no charge. Our address is: TEREX HANDLERS P.O. Box 790 Baraga, MI 49908-0790

CALIFORNIA Proposition 65 Waming Diesel engine exhaust and some of its constituents are known to the State of Califomia to cause cancer, birth defects, and other reproductive harm.

CALIFORNIA Proposition 65 Waming BattelY posts, terminals, and related accessOlies contain lead and lead compounds, chemicals known to the State of Califomi a to cause cancer and reproductive harm Batteries also contain other chemicals known to the State of California to cause cancer.

Wash hands after handling.

6-4